1

Need for Depression Air Compressor

Compressed Air is c|ean, safe, s|mp|e and eff|c|ent. There are no dangerous exhaust Iumes or other
harmIul by products when compressed air is used. It is a non-combustible, non-polluting utility.
The importance oI compressed air is oIten over looked, but in reality it plays a vital part in
modern power plants.

Compressed air system oI the power station is divided into two parts oI low pressure system
and medium pressure system.

1 Low Pressure Air System
Low pressure air system oI the power station supplies air Ior Iollowing purposes: air required
Ior unit braking ( Pressure req is 15 kgc/cm2 & has a consumption rate oI 8 ltrs/s Ior unit 1) and
standstill seal ie, maintenance seal etc.

2 Medium Pressure Air System
Medium pressure air system mainly supplies air Ior all the oil pressure units and Ior the
synchronous condenser generator mode oI turbine.

For this purpose , Iour number oI 3- Stage Double Acting Compressors oI Reciprocating type
are installed in the power house . Each compressor build up pressure oI 55 Kg/cm
2
. The
compressed air Irom the compressor is Ied into the common air line which is connected to the 14
No oI air Receiver tanks ( Units 7 *2 14 ). These Air receiver tanks have a volume oI 7700
liters. Thus the total volume oI air receiver tanks is 1,07,800 liters.
The Compressor are supplied by Kaji Iron Works , Japan













2

Specifications of Depression Air Compressor

Details of (D.A.C.)

Model : VD3-110-OL ( V-type , 2 cylinder , 3 stage, double action
,oil Iree type)
Speed : 480 RPM
Piston Displacement : 11.96 m
2
/min
Discharge Pressure : 55 Kg/cm
2
Power : 110 KW
Capacity oI Lubricant : 130 Lit
Make : KAJI IRON WORKS LTD.
MADE IN : JAPAN

Details of Motor

3 O - INDUCTION MOTOR , Fan Cooled Type
Make : Hitachi.
Type : EFOUP *
Capacity : 110 KW.
Volts : 415 V.
Frequency : 50 Hz
Poles : 6
Speed : 970 RPM,
Current : 185 Amps
Contactor : 'Hitachi Type. K 300EP K25 EP.
MCCB : 'Hitachi F400C . 3P
O/L. Relays. : Hitachi From TR .20. RTC.
C.Ts. : 300/5, VA15, 2.5 to 3.5
Amps. Brgs. : 220. & 6317
Ambient : 45
0
C.
Insulation . class : F **
Form : KK
Rating : CONT
Rotor : K
2
CODE : E
BRG .D.S : NU220
BRG.O.S : 6317
Rule : JIS-C4004
Protection : JP22S
Cooling : JCO

D.A.C.No-1 : Sl.No. G814288 D.A.C.No-2. : Sl.No. G814288
D.A.C.No-3 : Sl.No. G 814288 D.A.C.No-4 : SL.No. 868052
3

Specifications of Inter Coolers and Drain Seperators



Ist Stage Inter Cooler
SurIace Area : 4.45 m
2

Design Press & Temp
Tube Side : 9.9 Kg/cm
2
, 200
0
C
Shell Side : 8 Kg/cm
2
,100
0
C
Hydro Test Pressure
Tube Side : 15.87 Kg/cm
2

Shell Side : 13.4

Kg/cm
2


Ist stage Drain Seperator
Volume : 75 Lit.
Design Pressure : 9.9 Kg/cm2
Design Temperature : 200
0
C
Hydro Test Pressure : 15.87 Kg/cm
2
Make : KAJI IRON WORKS LTD.


II
nd
Stage Inter Cooler
SurIace Area : 2.8 m
2

Design Press & Temp
Tube Side : 20 Kg/cm
2
, 200
0
C
Shell Side : 8 Kg/cm
2
, 100
0
C
Hydro Test Pressure
Tube Side : 30 Kg/cm
2

Shell Side : 13.4 Kg/cm
2

II
nd
Stage Drain Seperator
Volume : 32.4 Lit.
Design Pressure : 20 Kg/cm
2

Design Temperature : 200
0
C
Hydro Test Pressure : 30 Kg/cm
2
Make : KAJI IRON WORKS LTD.
4



III
rd
Stage After Cooler

SurIace Area : 3.4 m
2

Design Press & Temp
Tube Side : 61.2 Kg/cm
2
, 200
0
C
Shell Side : 8 Kg/cm
2
, 100
0
C
Hydro Test Pressure
Tube Side : 92 Kg/cm
2

Shell Side : 13.4 Kg/cm
2


III
rd
Stage Drain Seperator
Volume : 24 Lit.
Design Pressure & Temp : 61.2 Kg/cm
2
, 200
0
C
Hydro Test Pressure : 92 Kg/cm
2
Make : KAJI IRON WORKS LTD.

Shaft Mounted Oil Pump

Type : 3RD-15TB
W.T.P : 6 Kg
MFG No : 81-G-5
Make : NIPPON GEROTOR CO.LTD





3

Solenoid Operated Cooling Water Valve

Serial No : HTSPR-40WMI
Media : Water
Size : 40
Maximum Temp : 60
0
C
Pressure : 0.3 10 kgI/cm
2

Voltage : 200 V AC
Frequency : 50 Hz
Type : Normally Close
Make : KEIHIN SEIKI








6

Suction Filter & Silencer
Type : CentriIix Seperator
Make : BURGESS-MIURA SILENCING INDUSTRY Co. LTD







Design Working

Flow Switch :

Two types oI Ilow switcthes are used.
1.FCD-SR
2.FCD-FO
FCD stands Ior the material Ductile Iron Casting

1. FCD-SR
SpeciIications :

Type : FC-SR
Fluid :Water
Max Pressure : 10 kgI/cm2
Contact :1 b (N.C)
Capacity : 100 VA/W
Max Switching Voltage : 200 V AC/DC
Max. Switching Current : 3 A
Make : Taiyo Valve M.F.G Co
D.W.G No : D6226
2. FCD-FO
SpeciIications:
Type : FC-SR
Fluid : Water
Max Pressure : 10 kgI/cm2
Type : Switchless Flow Switch
D.W.G.No :D6246

7

Solenoid Valve for Automatic Unloading & Drain Purpose:

Make : KEIHNIN
Type : M3P 3 Way Solenoid Valve



Cross Section of the Valve











8

Permissible Amplitude of Vibration

On the common base ( Vertical ) : Less than 3 ( SINGLE AMPLITUDE)
Crank shaIt : Less than 30( SINGLE AMPLITUDE)
Cylinder Head : Less than 100( SINGLE AMPLITUDE)
SurIace oI the Foundation : Less than 3( SINGLE AMPLITUDE)


Operating Pressure Settings
Alr compressor Maln SLarL - 32 SLop - 33
Alr compressor SLand by SLarL - 49 SLop - 33
normal-33 Alarm <46 and >37.3

Material Specifications of Important Components:
S.No Description Material Quantity Required
1 Piston Rod S45C 2 No`s
2 Piston Ring 300 O HC-2E3 2 Sets
3 Rider Ring 300 O HC-2E3 1 Set ( Split Type)
4 Tension Ring 300 O SWPA 2 No`s
5 Piston Ring 200 O KR 4 sets
6 Rider Ring 200 O PTFE.R3 1 No ( Single Piece)
7 Tension Ring 200 O SWPA 4 No`s
8 Piston Ring 100 O KR 7 Sets
9 Rider Ring 100 O PTFE 2 No`s ( Single Piece)
10 Tension Ring 100 O SWPA 7 No`s
11 Oil Seal NBR 2 * 2 No`s
12 Rod Packings 3P & 6P First Stage PTFER3(Packings)
SUS304(Spring)
3 Sets ( Set-3Piece)
3 Sets (Set- 6Pieces)
13 Rod Packings 3P & 6P -II & IIIrd stages KR (Packings)
SUS304(Spring) For 2 &
3 rd Stage
5 Sets ( Set-3Piece)
5 Sets (Set- 6Pieces)
14 Lubricant Oil Servo 100 130 Lit
15 Belts 5 No`s
16 Packing Material Heat Resistant Asbestos
Sheet 1 mm Thick


PTFE Poly tetra Iluoro ethylene
SUS304 Heat Resisting Stainless Steel.
S45C Medium Strength Steel
SWPA Low Alloy Spring Steel
9

Compressor Cross Sectional View

10


Exploded View of Rod Packing Assembly in 2D and 3D View

























11



Piston Rod packings are essential in preventing the leakage oI the air.
Piston rod packing is almost always the "Iull Iloating" type. It consists oI several annular cups,
segmental rings, and a Ilange-like gland held in the cylinder head stuIIing box as a complete
assembly by properly proportioned studs and nuts that secure it against a sealing gasket. The
segmental packing (sealing rings) is contained in the cups and is held together as an assembly by
garter springs that hold the rings Iirmly on the piston rod.
These rings are Iree to "Iloat" in the cups. This packing is essentially a precision mechanical seal
with ground or lapped surIaces. Although oI rugged construction, it must be careIully handled
and examined to see that it is clean and Iree oI nicks, burrs, and scratches on the sealing surIaces.

Rod Packing sets oI 5 No`s is required Ior the second stage and 3
sets are required Ior the Iirst stage.
Rod packings are two types ; 3P and 6P where P Stand Ior Pieces.
The rod packings are assembled Irom segments and Iinally held
by the garter spring which applies uniIorm pressure Irom the
backside.

It has a one room distance piece between the crankcase and
cylinder. So that the gas Irom the cylinder does not leak in the rod,
It is sealed with backing pressure.
Oil adhering to the piston rod Irom the crank chamber scraped in
oil seal, to prevent contamination oI oil to the cylinder Iurther.




During replacing the Rod Packing`s care should be given Ior
1. The packings which are spitable in 3 pieces should be placed on pressure side.
2. The packings should be assembled as per the notch marks provided on them. This
ensures the least amount oI leakage Irom the rod packings.
3. Never mix the old and new packing segments.

12


Exploded View of First Stage Piston Ring and Rider Ring assembly
Number of Piston Rings : 2
Number of Rider Rings : 1
13

Exploded View of 3 rd and 2 nd stage Piston ring and Rider Ring Assembly


Piston ring

The Piston Ring is to be in close contact to the
cylinder wall Irom the inside the ring which is divided
into three piece carbon Iiber -Fluorine resin (PTFE)
.Piston ring is the structure that is brought into close
contact to the cylinder wall by the tension ring.

Rider Ring

The rider ring, there is a (PTFE) made endless Iluorine
resin type (slip-over type) and special carbon steel,
which is divided into three pieces. Both are long liIe, It
can be used Ior a long period oI time endless type
structure because it is not aIIected at all oI the back
pressure in particular.

Number oI Piston Rings 3 rd stage : 7
Number oI Rider Rings 3 rd stage : 2
Number oI Piston Rings 2 nd stage : 4
Number oI Rider Rings 2 nd stage : 1
Number oI Oil Seals : 2












14

Exploded View of Suction and Discharge Valves





















Suction Valves for 1 st and 2 nd stages : 5 No`s (4 +1 )
Delivery Valves for 1 st and 2 nd stages : 5 No`s (4+ 1)
Suction Valve for 3 rd stage : 1 No
Delivery Valve for 3 rd stage : 1 No
13


Air Line Diagram in the Nagarjuna Sagar Main Power House




16

Schematic Diagram of Depression air Compressor

Air Compressor Top View











Technical Description of Depression Air Compressor



















Technical Description of Depression Air Compressor Technical Description of Depression Air Compressor
Foundation Details of the Compressor
Technical Description of Depression Air Compressor
Foundation Details of the Compressor
17
Technical Description of Depression Air Compressor
Foundation Details of the Compressor
Technical Description of Depression Air Compressor
Foundation Details of the Compressor Foundation Details of the Compressor

18




















Top View of the Compressor






Front View of the Compressor
19

Dimensions of the Compressor


































20

Instructions :
1. The popping pressure oI the saIety valve is to be set at a pressure 0.5 0.8 kg/cm2 more than
working pressure.
2. The head Ior cooling water should be in the range oI 10 ~15 m. The quantity oI the water should
be regulated ; iI more amount oI cooling water is provided then the cylinder will be greatly
cooled down thus causing moisture to condense in the cylinder inIlicting much harm to the
perIormance oI the piston ring.
On the whole , the adjustment should be so made that the temperature diIIerence between
that oI the inlet and that oI the outlet be made by 5~ 10
0
C.
3. The belt should be stretched careIully, neither too tight nor too loose. Although it depends on the
distance between the pulleys, an appropriate stretch may be obtained by making the loosening oI
the belt about twice the thickness oI the belt when the belt is pushed by hands.
4. For Packing materials, quality heat resistant asbestos sheet oI thickness 1 mm should be used.
5. Assembly oI piston rod and crosshead
a. With the pieces oI soIt Iuse etc, inserted Irom the hole oI the valve chest , the piston is
liIted and lowered to press then to crushing. Then their thickness are correctly measured.
The clearances between the upper and lower dead points oI the piston should be adjusted
to be 2 mm and 1 mm respectively.
b. Marking oI the nut and the piston rod should be done Ior the conIirmation oI Iastening.


























21

Information about Motor Specifications

* EFOUP -(Economical and general purpose-dryprooI type )

** Insulation Class F
IEC
60085
ThermaI
cIass
OId IEC
60085
ThermaI
cIass
NEMA
CIass
NEMA/UL
Letter
cIass
Maximum
hot spot
temperature
aIIowed
ReIative
thermaI
endurance
index (C)
TypicaI materiaIs
155 F 155 F 155C >155 - 180
Class 130 materials with binders
stable at the higher temperature, or
other materials with usable lifetime at
this temperature


PROTECTION - 1P22S

Class oI No.1 Symbol
Type Symbol Description
Protected 2 Constructed to prevent contact with rotating and conductive parts
inside the machine, by hand or other critical parts oI the humanbody. Constructed
to prevent penetration by solid substances over 12mm in diameter.
Class oI No.2 Symbol
Drip-prooI 2 Constructed to prevent harmIul eIIect Irom dripping water
Ialling Irom within 15direction Irom vertical.
S : Test oI Iorm oI protection against water permeation conducted when motor is stopped
1IS C 4004 (1992) : General rules Ior rotating electrical machines

22


The National Electrical Manufacturer's Association - who sets the design standards for motors, has
established a NEMA Code letter designation to classify motors by the ratio of locked rotor KVA per
horsepower.
NEMA
Code Letter
KVA/HP
with locked rotor
Approximate Mid-
Range Value
E 4.5-4.99 4.7



Definitions
1. Gauge pressure is the pressure, in kgI /cm
2
, above local atmospheric pressure.
2. Absolute pressure is the existing gauge pressure plus local atmospheric or barometric
pressure.
3. Displacement oI a compressor is the volume swept through the cylinder and is usually
expressed in m
3
/min
4. Free air is air at normal atmospheric conditions.
5. Actual capacity is a term that is sometimes applied to the capacity oI a compressor at
intake conditions.
6. Volumetric eIIiciency is the ratio oI the actual capacity oI the compressor to
displacement and is expressed as a percentage.
7. Compression eIIiciency is the ratio oI the theoretical horsepower to the actual indicated
horsepower required to compress a deIinite amount oI gas.
8. Mechanical eIIiciency is the ratio oI the indicated horsepower in the compressing
cylinders to the brake horsepower delivered to the shaIt. It is expressed as a percentage.
9. Overall eIIiciency is the product oI the compression eIIiciency and the mechanical
eIIiciency.
10. Frame load is the amount oI load or Iorce the compressor Irame and running gear (i.e.,
the connecting rod, bolts, crosshead, crosshead pin, piston rod, connecting rod bearings,
and crankshaIt) can saIely carry in tension and compression.
11. Compression ratio is the ratio oI the absolute discharge pressure) and the absolute inlet
pressure .
12. COMPRESSOR CAPACITY : Determining compressor capacity would be relatively
simple iI a noncompressible, non-expandable Iluid were handled. The quantity into the
discharge line would be practically equal to the volume swept by the piston.



23



13. INTERSTAGE PRESSURES :
a. P1 is Iirst-stage intake
b. P2 is Iirst intercooler
c. P3 is second intercooler
d. P4 is third-stage discharge